Lead sheet suspension stud

ABSTRACT

The present invention relates to an article of manufacture and a method of how to utilize the same in order to create a radiation leak-proof environment. The present invention further relates to a metal stud configured with two holding cavities wherein the first holding cavity and the second holding cavity are constructed so that when a lead sheet is held in the first holding cavity and wherein a lead sheet is held in the second holding cavity the lead sheets overlap, and thereby, create a radiation leak-proof metal stud system. 
     Additionally, what has been discovered is a radiation leak-proof barrier systems having a metal stud configuration that eliminates the need for a strip of lead behind the joints of abutting sheets of lead lined drywall; it eliminates the need to place lead buttons over the head of each screw used to attach the drywall to conventional metal stud systems; it eliminates the need for the installer to simultaneously handle both drywall and lead sheets; it reduces the potential for back injury to the installer by reducing material handling weight during construction, thereby, minimizes workers&#39; compensation claims; and, it reduces start to finish construction time, while providing maximum protection against radiation escape or leakage.

FIELD OF THE INVENTION

The present invention relates to an article of manufacture and a method of how to utilize the same. More particularly the present invention relates to a metal stud which is particularly suitable for suspending lead sheets that are used for radiology suite construction. Even more particularly, the metal stud of the present invention is easily installed, reduces the cost for construction, reduces the amount of labor needed to complete the job, it saves construction time and it is safer to use on-the-job in constructing x-ray and cat scan rooms and any other areas where radiation protection is needed.

BACKGROUND OF THE INVENTION

Generally, the methods for creating leak-proof lead barrier system that used metal studs and lead laminated gypsum board require the installer to countersink all of the drywall screws into the lead laminated gypsum board when securing the lead laminated gypsum board to the metal studs. Additionally, once the screws are countersunk in the gypsum board, lead screw caps slightly larger than the screw heads are positioned over each and every drywall screw. This is both costly in construction time and labor cost. Furthermore, in addition to the lead screw caps, a thin strip of sheet lead needs to be installed between the lead portion of the gypsum board and the metal stud where two or more sheets of lead laminated gypsum board are butted together to prevent leakage at the seam.

Other leak-proof lead barrier systems were allegedly created without the lead screw caps being installed over each and every screw or the narrow strip of sheet lead being installed at the seams.

While a further lead barrier system suggest that when a barrier portion of the lead barrier plate extends beyond the flanges of the metal stud, the countersunk holes and the lead strip added at juncture where the lead laminated gypsum boards abut, are no longer required.

All previously described methods for creating leak-proof lead barrier systems require extensive time consuming labor to install. In addition, the integrity of the gypsum in the lead laminated gypsum board is compromised due to countersinking of screws. Also, the use of lead screw caps causes cracks in the gypsum and may compromise the strength or the integrity of the drywall and therefore the strength or durability of the partition itself

Therefore, what has been found to be novel is a radiation leak-proof barrier system having a new metal stud configuration that eliminates the need for a strip of lead behind the joints of abutting sheets of lead lined drywall; it eliminates the need to place lead buttons over the head of each screw used to attach the drywall to conventional metal stud systems; it eliminates the need for the installer to simultaneously handle both drywall and lead sheets; it reduces the potential for back injury to the installer by reducing material handling weight during construction thereby, minimizes workers' compensation claims, and it reduces start to finish construction time, while providing maximum radiation protection.

SUMMARY OF THE INVENTION

A metal stud configured with two holding cavities wherein the first holding cavity and the second holding cavity are constructed so that when a lead sheet is held in the first holding cavity and wherein a lead sheet is held in the second holding cavity the lead sheets overlap, and thereby, create a radiation leak-proof metal stud system.

Given the fact that the lead sheets are held and suspended in the holding cavity between the metal studs and the drywall, no drywall screws will penetrate the lead sheets and compromise radiation protection, and, no screw caps are required with the present invention in order to maximize radiation protection.

Furthermore, with existing lead lined drywall systems, any electrical devices, such as for example, switches or receptacles, or plumbing fixtures, such as water supply lines, vacuum lines, require additional back-up lead installed with electrical and plumbing fixtures to keep radiation from escaping through penetrations resulting when electrical and plumbing fixtures disturb the integrity of the drywall. The present invention requires no additional back-up lead to accommodate switches or receptacles, or plumbing fixtures while maximizing radiation containment in the x-ray room.

It is therefore an object of the present metal stud leak-proof barrier system to eliminate the need for a strip of lead behind the joints of abutting sheets of lead lined drywall.

Another object of the present invention is to eliminate the need to place lead buttons over the head of each screw used to attach the drywall to conventional metal stud systems.

An additional object of the present invention is to eliminate the need for simultaneously having the installer handle both drywall and lead sheets.

A further object of the present invention is to reduce the potential for back injury to the installer by reducing material handling weight during construction of x-ray and cat-scan rooms.

Still another object of the present invention is to minimize employee lost time due to work related injuries and accompanying workers' compensation claims.

Still a further object of the present invention is to reduce the start to finish construction time, while maximizing radiation protection.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding of the invention are incorporated herein and constitute a part of this specification's illustration of the present invention. These and other features, aspects, and advantages of the present invention will become even better understood with regard to the following detailed description, appended claims, and accompanying drawings where:

FIG. 1—Illustrates a full scale view of the 20 Gauge sheet metal stud, that is consistent with the present invention and suitable for suspending and holding and overlapping lead sheets in order to maximizing radiology suite containment.

FIG. 2—Shows the proper way to use the metal stud 20 of the present invention in radiation proofing any corner of a room where the objective is to maximize the containment radiation and the preventing radiation from escaping.

FIG. 3—Shows the proper way to use the metal stud 20 of the present invention to prevent the escape of radiation around electrical receptacles that are necessary, however, at the same time, the receptacle provides a way for radiation to escape from the x-ray room. In order to prevent the radiation from escaping through a wall having an electrical receptacle using prior construction methods, it was time-consuming, labor-intensive and costly. The present invention resolves these problems because the lead sheets being held by holding cavities 26 and 27 allow for the construction and placement of the electrical receptacles into and within the drywall 33 without compromising the lead sheets 28 or radiation protection. This is accomplished, as illustrated in FIG. 3, because the holding cavities 26, 27 allow the lead sheets 28 to be held in each cavity in a manner that maximizes radiation containment in the x-ray room, while simultaneously, providing space for the electrical receptacle to be placed into and mounted in the drywall, without compromising the lead sheets 28 with, for example, any mounting screw-holes, which result in radiation escaping.

FIG. 4.—Shows the proper way to use the metal stud 20 of the present invention to prevent the escape of radiation around plumbing fixtures.

DETAILED DESCRIPTION OF THE INVENTION

A metal stud system for accepting and suspending lead sheets for radiology suite construction wherein the metal stud is configured to have two holding cavities wherein the first holding cavity and the second holding cavity are constructed and aligned along a vertical plane so that when a lead sheet is held in the first holding cavity and a lead sheet is held in the second holding cavity, the lead sheets overlap, and thereby, create a radiation leak-proof metal stud system.

FIG. 1 illustrates a full scale view of the radiation leak-proof sheet metal stud, 20, suitable for suspending lead sheets for radiology suite construction in the present invention. The metal stud, 20, of the present invention is created by two holding cavities, 26 and 27 respectively. The first holding cavity 26 is configured and aligns along the central planar portion, 23, and extends inwardly between the front planar portion 21 of the metal stud, 20, and the rear planar portion 22 as illustrated. The second holding cavity 27 is constructed and aligned along the central planar portion 23 and extends outwardly from the central planar portion 23, as illustrated, and the second holding cavity 27, extends in the opposite direction of first holding cavity 26, as illustrated. Each metal stud 20 of the present invention has a front planar portion 21 and, a rear planar portion 22 which extend outwardly from a central planar portion 23 and wherein flanges 24 and 25 extend inwardly form the front planar portion 21 and the rear planar portion 22, as shown. The holding cavities, 26 and 27 respectively, are aligned along the central planar portion 23, so that when a lead sheet is introduced and held by cavity 26, and a second lead sheet is introduced and held by cavity 27, both lead sheets overlap at a point where instead of creating an abutment of two lead sheets with accompanying issues of countersunk screws, screw caps, added strips of lead and lead barrier plates, the overlap maintains the integrity of the radiation leak-proof system; the overlap enables the lead sheets to extend over and completely cover cavity 26 and 27 eliminating any potential to compromise the radiation leak-proof system; and the overlap eliminates abutting lead sheets during construction thus creating the radiation leak-proof metal stud 20 of this invention.

The metal stud 20 of the present invention is manufactured using 20 (twenty) gauge sheet metal.

The holding cavity 26 and 27 of the present invention are from about one-eighth inch ⅛″ thick to about one-half ½ inch thick, and from about by one inch 1″ deep to about one (1) and one-half ½ inch deep, depending on the application. When the workman is installing lead sheets the holding cavity is about ⅛ inch thick and one inch deep. However, when the workman is installing acoustical sound modifying sheets, and the like, the metal stud would require a thicker and possibly deeper cavity. Both holding cavities 26 and 27, are located along the central planar portion 23 of metal stud 20 and are specifically designed, constructed and configured to eliminate abutting lead sheets; to eliminate the need for lead strip at the abutment point; to eliminate the need for lead buttons on the head of drywall screws and, thereby create, radiation leak proof suites. It should be understood that the present design of the holding cavities, 26 and 27, may be modified to accept thicker materials, and may be further modified to create holding cavities deeper than one (1) inch.

The lead sheets are held in the holding cavities 26, and 27, by a number of ways known in the art. The installer could use a construction adhesive, such as “Liquid Nail” which available from any construction material supply house, such as, for example, Lowe's, Home Depot. The liquid nail is inserted into the cavity before inserting the lead sheet. In an alternate method, after inserting the lead sheet into the cavity, the installer may pinch, crimp, compress, the cavity using pliers or C-Clamps with a set-screw in order to grip the lead sheet.

FIG. 2-Shows the proper way to utilize the metal stud 20 of the present invention where the objective is to maximize the containment of radiation and preventing the radiation from escaping by radiation proofing any corner of a room constructed using abutting or intersecting dry wall 33 at the corners. In order to prevent radiation form escaping at the intersection, lead sheet 28 is utilized as illustrated in cavity 26 of metal stud 20 so as to overlap with the lead sheet utilized in cavity 27 thereby creating maximum containment of the radiation for any corner construction.

FIG. 4—Shows the proper way to use the metal stud 20 of the present invention to prevent the escape of radiation around plumbing fixtures that are necessary, however, at the same time, they provides a way for radiation to escape from the room. In order to prevent radiation from escaping around plumbing fixtures using prior construction methods, it was time-consuming, labor-intensive and costly. The present invention resolves these problems because the lead sheets allow for the construction of all plumbing fixtures without compromising the lead sheets with plumbing fixture holes and the room with radiation protection. This is accomplished, as illustrated in FIG. 4, because the holding cavities 26, 27 allow the lead sheets to be held in a manner that maximizes radiation containment in the x-ray room, while simultaneously, providing space for the plumbing fixtures to be placed into and through the drywall, without compromising the lead sheets with plumbing fixture holes. 

1. A radiation leak-proof metal stud system comprising: A metal stud configured with two holding cavities wherein the first holding cavity and the second holding cavity are constructed so that when a lead sheet is held in the first holding cavity and wherein a second lead sheet is held in the second holding cavity the lead the first holding cavity and the lead sheet in the second holding cavity overlap, and thereby, create a radiation leak-proof metal stud system.
 2. The radiation leak-proof metal stud system of claim 1 wherein the lead sheet are held in the first holding cavity and the second holding cavity by a construction adhesive.
 3. The radiation leak-proof metal stud system of claim 2 wherein the construction adhesive is liquid nail.
 4. The radiation leak-proof metal stud system of claim 1 wherein the lead sheet are held in the first and the second holding cavity by using pliers to pinch, to crimp, to compress, the holding cavity onto and against the lead sheets
 5. The radiation leak-proof metal stud system of claim 4 wherein the lead sheet are held in the holding cavity by using C-Clamps with a set-screw in order to grip the lead sheet.
 6. The use of the radiation leak-proof metal stud system of claim 1 in order to prevent the escape of radiation around electrical receptacles in x-ray room.
 7. The use of the radiation leak-proof metal stud system of claim 1 in order to prevent the escape of radiation around plumbing fixtures in x-ray room.
 8. The use of the radiation leak-proof metal stud system of claim 1 in order to prevent the escape of radiation for any corner of x-ray room.
 9. A method for building a radiation leak-proof room comprising: using a metal stud configured with two holding cavities wherein the first holding cavity and the second holding cavity are constructed so that when a lead sheet is held in the first holding cavity and wherein a second lead sheet is held in the second holding cavity the lead the first holding cavity and the lead sheet in the second holding cavity overlap, and thereby, create a radiation leak-proof metal stud system. 